Method for forming a carton with integral handle

ABSTRACT

A carton formed from a single blank of material comprising pairs of top flaps foldably attached to adjacent side walls, with integral handle flaps foldably attached to each other and to the top flaps, wherein by proper manipulation of the top flaps and handle flaps, the carton is closed to automatically align the handle flaps in an upright position.

Umted States Patent I 1 91 1111 3,776,108 Nock 1451 Dec. 4, 1973 [54] METHOD FOR FORMING A CARTON WITH 3,365,134 1/1968 Oberreich 229/39 R INTEGRAL HANDLE FOREIGN PATENTS OR APPLICATIONS Inventor: J Nock, New Castle, 1361- 598,538 10/1959 Italy 229/52 B 1,180,160 12/1958 France 229/52 B [73] Ass'gnee' gs corporat'on New York 1,422,235 11/1965 France 229 52 B [22] Filed: Aug. 4, 1972 Primary Examiner- Davis T. Moorhead [211 pp No 277 880 Att0rne yLarry C. Hall et a1.

57 ABSTRACT [52] US. Cl. 93/39 R, 225/52 B, 229/39 R 1 51 Int. Cl... B65d 5/46 A carton from a Smgle blank of mammal [58] Field of Search 229/39 R, 41 B, 52 B; prising Pairs of top flaps foldably attached to adjacent 93 R side walls, with integral handle flaps foldably attached to each other and to the top flaps, wherein by proper [56] References Cited manipulation of the top flaps and handle flaps, the

UNITED STATES PATENTS carton is closed to automatically align the handle maps in an upright position. 2,900,124 8/1959 Leone 229/52 B 2,903,180 9/1959 Holmes 229/41 B X 4 Claims, 8 Drawing Figures METHOD FOR FORMING A CARTON WITH- INTEGRAL HANDLE SUMMARY OF INVENTION The present invention relates generally to a box-like carton formed of paperboard or the like and more particularly to a top construction for folding cartons wherein a top and handle are formed when the carton is erected.

The folding carton in accordance with the present in-.

vention is produced from a single blank of material and includes a novel top closure structure whichcomprises integral top flaps and a carrying, handle which are.

formed automatically when the carton is erected and closed. The carton is glued on the machine in the configration of a flat tube having sidewalls with closure flapsattached to eachend thereof. Accordingly, the carton thus formed is readily shipped'to the ii'serin itsoriginal' flat condition, and in that condition it occupies a minimum of space both during storage and transit. Of'

course, the carton is quickly and easily folded intoits box-like form when required for use, and insodoing, the flaps which form the top and handle are so arranged that, when the cartonis squared, and the top'flaps arefolded over the top of the carton body, the handle portions of the top flaps automatically assume their upright carrying position. Furthermore, as will-(be appreciated from additional study of the present invention, the novel arrangement of the top flaps and handle provided herein offers at least two different methods for'closing the top of the carton and forming the handleportion thereof.

In a preferred embodiment of the folding carton of the present invention, four top flaps are attachedto respective side walls of a tapered, rectangular carton body with the top flaps arranged in pairs, and with flaps of the respective pairs being attachedto adjacent side walls. Each of the top flaps also include, as an integral portion thereof, the novel handle flaps disclosed, with:

the handle flaps of a respective pair of top flaps being joined to each otheralong a fold line. The handle flaps also have matching openings cutthereinto provide a space for gripping or carrying the carton. In addition,

in accordance with the preferredembodiment just described, the folding carton also includes four bottom closure flaps attached to the respective side walls of the carton body, which may be in the'form ofaconventional self locking bottom closure that is easily set upthe exposed peripheral surfaces of the carton provide ample area for display and/or printedadvertising messages. In particular, it may be appreciated that the overall design andmechanism wherebyv the carton of the present invention is manipulated forclosure is quite eye catching and visually appealing.

DESCRIPTION OF DRAWING FIG. 1 is a plan view of a blank form from which the carton of the present invention might be constructed;

FIG. 2 is a prerspective view showing a first step in one of the folding sequences that may be used toclose the top of the carton;

FIG. 3 is a perspective view showing the second step in the folding sequence illustrated in FIG. 2;

FIG. 4 is a perspective view showing a completely foldedcanon as illustrated in FIGS. 2 and 3;

FIG. 5 is a perspective view showing a. first step in a second scheme that may be used to close the top of the carton disclosed;

FIG. 6 is a perspective view showing the completely closed carton as illustrated in FIG. 5;

FIG. 7 is a partial perspective showing a locking feature that could be added to the embodiment of FIGS. 5 and 6; and,

FIG. 8 is a detailed sectional view' taken along the line 8-8 of FIG. 7 showing the locking feature'ofFlG: 7 in the closed condition of the carton.

DETAILED DESCRIPTION In the carton of the present invention, top flaps are foldably attached to the respective side walls of a carton body, and the topflaps are arranged in pairs with flaps of the respectivepairs being attached to adjacent Referring more particularly toFIG. I, a blank is shown from which a-tapered carton of the present invention may be formed. The blank. contains, in the exemplary embodiment'shown, four side walls 10, l2, l4 and 16 which are spearated from one another by suitable'fold lines 11, 13 and l5. Each of the walls are.

shown as being slightly tapered along their length to achieve the illustrated tapered final configuration, al

though it should be understood that a squared carton I could just as readily be constructed if desired without deviating from the invention disclosed. A flap extension 18 is shown as being attached along fold line 17 to wall 16, which is used ultimately to secure the carton together in its erected condition. Generally, the carton is glued together in its folded and flat condition, however any other desirable form of securing flap 18 to wall 10 could be used. After flap 18 is secured, the carton is then shipped to the user in its flat, collapsed condition where it is then set up and filled.

' FIG. 1 also shows the preferred embodiment of a selflocking bottom closure of more-or-less conventional.

design. Of course, any other similar design could just as readily be used to satisfy the same purpose without the exercise of invention. Bottom closureflaps 19, 21, 23 and 25 are illustrated as being foldably attached along foldlines 20, 22, 24 and 26 to the side wall panels 10, 12, 14 and 16 respectively. In order to set up the bottom closure shown, the proper sequence would be to initially square the carton which has been previously glued or otherwise secured. Secondly, bottom flap 21 would be folded along fold line 22 to a position perpendicular to the side wall 12. Thirdly, the two bottom flaps 19, 23 would be folded along fold lines 20, 24 into an overlapping relationship with flap 21. Fourth, the remaining bottom closure flap 25 would then be folded along fold line 26 to permit the tab 47 on the extreme end of flap 25 to be inserted in the cut out 48 of panel 21. In order to carry out these different steps, it is necessary to initially force all of the flaps into the interior of the carton so that the tab 47 can be inserted in the cut out 48 without bending or otherwise mutilating the tab. Once the bottom closure is thus set up, the natural tendency for the carton material is to spring back to its original position and produce astrong bottom.

The novel top closure and integral handle for the carton disclosed herein is formed from the paired closure flaps 28, 34 and 38, 44, attached to the respective side walls 16, 14 and 12, 10. The top closure flaps 2 8 and 34 are attached to side walls 16 and 14 along fold lines 27 and 33 respectively and are scored along diagonal score lines 29 and 35 to form the handle portions 30 and 49. As will be noted from the drawing, and particularly in FIG. 1, the diagonal score lines 29, each emanate from the intersection of the score lines 15, 27 and 33 which further define two adjacent sides 16, 14 of the carton. Thus, the diagonal score lines 29, 35 serve to define triangular top closure flaps 28, 34 and triangular handle flaps 30, 49. In addition, each of the handle flaps 30, 49 contain hand grip cut outs 31, 36 and they are also separated from one another along the fold line 32.

The second pair of top closure flaps illustrated are the flaps 38 and 44. Each of these flaps are connected to adjacent side walls 12 and 10 along the fold lines 39 and 43 respectively. Further, as in the case of the paired closure flaps 28, 34, closure flaps 38, 44 are each further divided diagonally by the score lines 40, 45 todefine their own triangular shape and also define handle flaps 50, 51 of a similar triangular shape. As before, the handle flaps 50, 51 are joined to one another along the fold line 42, and in each case, each handle flap 50, 51 contains a matching hand grip cut out 41, 40.

Accordingly, as thus far described, the invention consists of a more-or-less conventional tapered carton having four side walls, a self-locking bottom closure, and a series of uniquely scored top closure flaps consisting .of triangular shaped top flaps 28, 34, 38 and 44 and integral triangular shaped handle flaps 30, 49, and 51.

However, the novelty of the present invention lies in a combination of the manner in which the top closure flaps are scored and in the way and sequence used to fold the top closure flaps into a closed condition. In this regard, it is contemplated that there are at least two folding schemes that may be used to close the top of the carton disclosed herein and automatically set up the handle portion thereof. FIGS. 2-4 show one method for forming the top closure and FIGS. 5 and 6 show a second scheme.

In FIG. 2, it will be noted that according to the first method for forming the top closure, the first step in securing the top of the carton comprises the simultaneous folding of top closure flaps 34 and 44 about their respective fold lines 33 and 43. This step is accomplished by pushing down on flaps 34 and 44 and at the same time initiating a reverse fold along the fold lines 35 and 45 to bring the associated handle flaps 49 and 51 into upstanding, side-by -side relationship. For the sake of description, these two folds are labeled folds A" and B on the drawing in FIG. 2. In this condition, the top of the carton is actually fully coveredsince the two top flaps 34, 44 are each sized to cover one-half of the top, however the remaining top flaps 28 and 38 remain unclosed and extend away from the carton in diverging planes. Thus, for the purpose of completely closing the carton, a second step is shown in FIG. 3 wherein the top flap 28 is folded down and into overlapping relationship with flap 44. This step is accomplished,as before in the case of top flaps 34, 44 by initiating a reverse fold along fold line 29 to bring the handle flap 30 into an upstanding and side-by-side position with respect to handle flaps 49 and 51. For the sake of description, this folding step is labeled C in FIG. 3. Finally, the completely enclosed and set-up carton is finished with the fold labeled D" in FIG. 4. For this purpose, top flap 38 is folded downwardly over the top flap 34 while simultaneously back folding handle flap 50 along fold line 40 to bring the flap 50 into its upstanding and side-by-side position with respect to handle flaps 30, 49 and 51. Accordingly, FIG. 4 shows the closed carton according to the first method contemplated with the handle flaps 30, 49,50, 51 extending upwardly and diagonally across the top of the carton. It may be appreciated moreover, that the top closure couldreadily be unfolded so as to openthe carton by performing the reverse of the steps just outlined.

Thus it may be seen that a unique carton top and closing sequence has been discovered and described herein to fully carry out the objects of the present invention. However, for the purpose of illustrating another useful scheme whereby the top portion of the carton of the present invention might be closed, reference should be made to FIGS. 5 and 6 herein where a second method is illustrated.

FIG. 5 illustrates the first step in the second method wherein two adjacent handle flaps 50, 51 are held together and pushed downward to cause the top flaps 38, 44 to fold downward simultaneously along their fold lines 39, 43. This step is illustrated on the drawing as comprising the folds at E" and F. Subsequently, the carton closure and handle erection is completed by grasping the remainingtwo handle flaps 30, 49, and, while holding them together, pushing the handle portions 30, 49 downwardly to lie on each side of the handle portions 50,51. This motion, as before, causes a simultaneous movement of the top flaps 28, 34, as shown at G and H in FIG. 6, into overlying relationship with the top flaps 38, 44. Thus the carton illustrated is again in a closed condition with the handle flaps 39, 49, 50, 51 extending upwardly therefrom, and diagonally across the top of the carton as shown in FIG. 6.

Later on, it was discovered that the second method of closing the carton just described did not always obtain a tight and secure closure. Apparently, when the cuts and scores in the top closure flaps 28, 34, 44 and handle flaps 30, 49, 50, 51 were not performed precisely, the second step of the second scheme (folds 6" and I-I) did not stay folded, but tended to spring up. Accordingly, to ofiset this tendency to spring open in some examples, the addition of a locking means associated with the handle flaps was added for securing the handle portions 30, 49, 50 and 51 together. For this purpose, and as shown in FIG. 7, small securing tabs and 61 were added to the first folded handle portions 50 and 51 and later folded around to lock the second folded handle portions 30, 49 in place. Of course, it may be appreciated that other forms of locking tabs and/or tabs and slots could be added to secure the handle portions of those cartons according to FIGS. -8 which tended to spring open. It should be emphasized however that the necessity for the locking tabs only occurred in some of the samples prepared and it is believed that for most instances no locking means would be required.

From the above description, it is believed that the construction and advantages of the carton hereinabove described will be readily apparent to those skilled in the art. It is also believed to be obvious that various modifications as to details of construction may be made without departing from the scope of the invention as defined in the appended claims.

I claim:

1. The method for forming a carton from a single blank of foldable material said blank consisting of a plurality of side walls connected together along fold lines to form a rectangular carton body portion, top closure flaps foldably attached to the upper edges of the respective side walls and bottom closure flaps foldably attached to the lower edges of the respective side walls, said top closure flaps being arranged in pairs and attached to adjacent side walls and including diagonal sore lines which emanate from the intersection of the fold lines between the two adjacent side walls and the foldable connection between the paired top closure flaps and the adjacent side walls, said diagonal score lines forming paired handle flap portions and top flap portions of the top closure flaps, said handle flap portions being further attached to one another along a fold line which is substantially a continuation of the fold line connecting the two adjacent side walls together, the improvement comprising the method for closing said carton and automatically aligning the handle flap portions in an upright position wherein:

a. the first step for securing the top of the carton comprises the simultaneous folding of two opposed top flap portions into a closed condition about the fold lines connecting said top flap portions to-the carton side walls to initiate a reverse fold along the diagonal score of each top closure flap and thereby bring the handle portions thereof into upstanding, side-by-side relationship; and,

b. a second step wherein the remaining top flap portions are folded into a closed condition about the lines connecting said top flap portions to the carton side walls to initiate reverse folds along the diagonal score of each remaining top closure flap and thereby bring the handle portions thereof into upstanding, side-by-side relationship.

2. The method of claim 1 wherein the second step of paragraph (b) comprises a sequential folding of each of the remaining top flap portions into their closed condition.

3. The method for forming a carton from a single blank of foldable material said blank consisting of a plurality of side walls connected together along fold lines to form a rectangular carton body portion, top closure flaps foldably attached to the upper edges of the respective side walls and bottom closure flaps foldably attached' to the lower edges of the respective side walls, said top closure flaps being arranged in pairs and attached to adjacent side walls and including diagonal score lines which emanate from the intersection of the fold lines between the two adjacent side walls and the foldable connection between the paired top closure flaps and the adjacent side walls, said diagonal socre lines forming paired handle flap portions and top flap portions of the top closure flaps, said handle flap portions being further attached to one another along a fold line which is substantially a continuation of the fold line connecting the two adjacent side walls together, the improvement comprising the method for closing said carton and automatically aligning the handle flap portions in an upright position wherein:

a. the first step for securing the top of the carton comprises holding two adjacent handle flap portions together and pushing downwardly to cause the attached top flap portions to simultaneously fold downwardly along the fold lines which connect the top closure flaps to the adjacent side walls; and,

b. secondly, grasping the remaining two adjacent handle flap portions together and pushing downwardly to cause the remaining two adjacent handle flap portions to fold in an overlapping relationship with the first two handle flap portions and cause the attached top flap portions to simultaneously fold downwardly along the fold lines which connect the remaining top closure flaps to the adjacent side walls and overlie the first folded top flaps.

4. The carton of claim 3 wherein lock tab elements are connected to the handle flap portions for locking the folded flap portions in the closed condition. 

1. The method for forming a carton from a single blank of foldable material said blank consisting of a plurality of side walls connected together along fold lines to form a rectangular carton body portion, top closure flaps foldably attached to the upper edges of the respective side walls and bottom closure flaps foldably attached tO the lower edges of the respective side walls, said top closure flaps being arranged in pairs and attached to adjacent side walls and including diagonal sore lines which emanate from the intersection of the fold lines between the two adjacent side walls and the foldable connection between the paired top closure flaps and the adjacent side walls, said diagonal score lines forming paired handle flap portions and top flap portions of the top closure flaps, said handle flap portions being further attached to one another along a fold line which is substantially a continuation of the fold line connecting the two adjacent side walls together, the improvement comprising the method for closing said carton and automatically aligning the handle flap portions in an upright position wherein: a. the first step for securing the top of the carton comprises the simultaneous folding of two opposed top flap portions into a closed condition about the fold lines connecting said top flap portions to the carton side walls to initiate a reverse fold along the diagonal score of each top closure flap and thereby bring the handle portions thereof into upstanding, side-by-side relationship; and, b. a second step wherein the remaining top flap portions are folded into a closed condition about the lines connecting said top flap portions to the carton side walls to initiate reverse folds along the diagonal score of each remaining top closure flap and thereby bring the handle portions thereof into upstanding, side-by-side relationship.
 2. The method of claim 1 wherein the second step of paragraph (b) comprises a sequential folding of each of the remaining top flap portions into their closed condition.
 3. The method for forming a carton from a single blank of foldable material said blank consisting of a plurality of side walls connected together along fold lines to form a rectangular carton body portion, top closure flaps foldably attached to the upper edges of the respective side walls and bottom closure flaps foldably attached to the lower edges of the respective side walls, said top closure flaps being arranged in pairs and attached to adjacent side walls and including diagonal score lines which emanate from the intersection of the fold lines between the two adjacent side walls and the foldable connection between the paired top closure flaps and the adjacent side walls, said diagonal socre lines forming paired handle flap portions and top flap portions of the top closure flaps, said handle flap portions being further attached to one another along a fold line which is substantially a continuation of the fold line connecting the two adjacent side walls together, the improvement comprising the method for closing said carton and automatically aligning the handle flap portions in an upright position wherein: a. the first step for securing the top of the carton comprises holding two adjacent handle flap portions together and pushing downwardly to cause the attached top flap portions to simultaneously fold downwardly along the fold lines which connect the top closure flaps to the adjacent side walls; and, b. secondly, grasping the remaining two adjacent handle flap portions together and pushing downwardly to cause the remaining two adjacent handle flap portions to fold in an overlapping relationship with the first two handle flap portions and cause the attached top flap portions to simultaneously fold downwardly along the fold lines which connect the remaining top closure flaps to the adjacent side walls and overlie the first folded top flaps.
 4. The carton of claim 3 wherein lock tab elements are connected to the handle flap portions for locking the folded flap portions in the closed condition. 